KTM 125 EXC EU 2013 Manual

SETUP INSTRUCTIONS 2013
125 EXC EU
125 EXC SIX DAYS EU
200 EXC EU
200 EXC AUS
200 XC‑W USA
250 EXC EU
250 EXC AUS
250 EXC SIX DAYS EU
250 XC‑W USA
300 EXC EU
300 EXC AUS
300 EXC SIX DAYS EU
300 XC‑W USA
Art. no. 3211909en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2012 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

1 MEANS OF REPRESENTATION 2
1.1 Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Indicates a page reference (more information is provided on the specified page).
Indicates information with more details or tips.
Indicates the result of a testing step.
Denotes a voltage measurement.
Denotes a current measurement.
Denotes a resistance measurement.
1.2 Formats used
The typographical formats used in this document are explained below.
Proprietary name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

2 SETUP 3
2.1 Unpacking and setting up the vehicle
B00887-01
Packaging 2
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Carefully loosen and remove the footrest mount.
Info
An assistant prevents the motorcycle from falling over.
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
600811-10
Package 12
–Remove the box and the plastic packaging.
Info
An assistant prevents the motorcycle from falling over.
To avoid damaging the motorcycle during the setup, leave the protective
film on the vehicle until you have finished.
–Remove the separate enclosure and unpack it. Check that the scope of delivery
is complete on the basis of the enclosed packing list.
–Have a lift stand available.
Lift stand (54829055000)
–Together with an assistant, take the vehicle off the palette.
–Position the vehicle on a lift stand.
–Check the vehicle for transport damage.
B00902-01
–Install the shock absorber. ( p. 9)
600814-01
–Route the clutch line with the clutch master cylinder toward the front between
the upper and lower triple clamps.
(125 EXC EU, all 200 models, 250/300 EXC EU, EXC AUS, XC‑W)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 20 Nm
(14.8 lbf ft)
Screw, bottom triple clamp M8 15 Nm
(11.1 lbf ft)
Info
The topmost milled groove in the fork leg must be flush with the top
edge of the upper triple clamp.
Position the bleeder screws toward the front.

2 SETUP 4
(250/300 EXC SIX DAYS EU, 125 EXC SIX DAYS EU)
–Position the fork legs and tighten the screws of the triple clamp.
Guideline
Screw, top triple clamp M8 17 Nm
(12.5 lbf ft)
Screw, bottom triple clamp M8 12 Nm
(8.9 lbf ft)
Info
The rebound damping is located in the right fork leg (red adjust-
ing screw). The compression damping is located in the left fork leg
(white adjusting screw).
The topmost milled groove in the fork leg must be flush with the top
edge of the upper triple clamp.
Position the bleeder screws toward the front.
400223-10
–Remove screws 1. Remove the handlebar clamps.
–Remove screws 2. Remove the handlebar supports.
–Place the handlebar supports in the required position. Mount and tighten
screws 2.
Guideline
Screw, handlebar support M10 40 Nm
(29.5 lbf ft)
Loctite®243™
Info
Position the left and right handlebar supports evenly.
600824-10
–Position the handlebar.
Info
Make sure cables and wiring are positioned correctly.
–Position the handlebar clamps. Mount and tighten the screws.
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
The markings on the handlebar should be at the center of the handlebar
clamps.
Keep the gap widths equal when tightening.
B00903-10
(All EXC models)
–Insert the indicator lamp with the blue and brown cable colors into socket 3.
–Insert the indicator lamp with the blue and violet cable colors into socket 4.

2 SETUP 5
B00904-10
(XC-W)
–Connect pull switch 5with the yellow and white cables.
401408-01
(All EXC models)
–Attach the retaining bracket for the connector, the turn signal bracket with the
turn signal, and the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
401409-01
(XC-W)
–Attach the speedometer to the upper triple clamp.
Guideline
Remaining screws, chassis M6 10 Nm
(7.4 lbf ft)
B00096-10
–Position the controls on the right half of the handlebar.
Info
The routing of the cables can be seen in the figure.
600817-10
–Position the controls on the left half of the handlebar.
Info
The figure shows how to route the clutch line and wiring harness.
201945-10
(All EXC models)
–Mount and tighten nuts 6of the turn signals on both sides.
–Connect connector 7of the right turn signal with connector 8, which is
marked green.
–Connect connector 9of the left turn signal with connector bk, which is marked
red.
–Connect the plug of the electric starter button to connector bl.

2 SETUP 6
401382-01
(All EXC models)
–Mount the turn signal switch.
–Install the front fender. ( p. 12)
–Correctly mount the fuel tank breather.
–Refit the headlight mask with the headlight. ( p. 12)
B00907-01
–Mount the handlebar cushion.
800042-10
–Mount the footrests with the springs and bolts. Secure the bolts using the washers
and pins.
Pliers for footrest spring (58429083000)
B00908-01
(All EXC models)
–Mount the license plate holder with the license plate lamp, turn signals, and
reflector.
–Connect the electrical components.
–Connect the connector of the left turn signal with connector that is marked red.
–Connect the connector of the right turn signal with the connector that is marked
green.

2 SETUP 7
800035-10
(All 200/250/300 models)
Warning
Risk of injury Battery acid and battery gases cause serious chemical
burns.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open flames. Charge only in
well-ventilated areas.
–In the event of skin contact, rinse with large amounts of water. If
battery acid gets in the eyes, rinse with water for at least 15 minutes
and contact a physician.
–Fill the battery.
Info
Read the notes in the battery package.
–Recharge the battery. ( p. 10)
–Install the battery. ( p. 11)
B00097-01
–Unpack and mount the KTM PowerParts included in the delivery (optional).
Info
Read the accompanying KTM PowerParts installation instructions.
–Apply the label included in the delivery (optional).
101037-01
(All EXC models)
–Mount the mirror clamps on both sides.
B00909-01
–Mount and tighten the rear mirror on both sides.
–Mount the reflector.
–Position all controls in their exact positions on the handlebar. Tighten all screws.
–Refuel. ( p. 14)
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

3 WORK 8
3.1 Raising the motorcycle with the lift stand
B00796-01
(All 125/200 models)
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (54829055000)
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
B00803-10
(All 250/300 models)
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
–Raise the motorcycle at the frame underneath the engine.
Lift stand (54829055000)
The wheels must no longer touch the ground.
–Secure the motorcycle against falling over.
3.2 Removing the motorcycle from the lift stand
Note
Danger of damage The parked vehicle may roll away or fall over.
–Always place the vehicle on a firm and even surface.
B00789-10
(All 125/200 models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with
the rubber band.
B00802-10
(All 250/300 models)
–Remove the motorcycle from the lift stand.
–Remove the lift stand.
–To park the motorcycle, press side stand 1to the ground with your foot and
lean the motorcycle on it.
Info
When you are riding, the side stand must be folded up and secured with
the rubber band.
3.3 Removing the seat
B00817-10
–Remove screw 1. Lift up the seat at the rear, pull it back and then remove from
above.